Flexible material

ABSTRACT

A flexible material includes a plurality of separate resilient elements joined to a flexible, resiliently stretchable substrate. Such a material is suitable for providing protective war for human and animal bodies. Preferably, the elements includes a foam material such as a closed cell polyethylene foam and the substrate includes a knitted fabric. In an advantageous embodiment, a second flexible substrate is bonded over the elements to sandwich them between the two layers of substrate.

RELATED U.S. APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO MICROFICHE APPENDIX

Not applicable.

FIELD OF THE INVENTION

The present invention relates to a method of manufacturing a flexiblematerial suitable, primarily, for use as a flexible protective materialto protect for human and animal bodies.

BACKGROUND OF THE INVENTION

Protective material and protective wear is currently used by persons toprotect themselves from knocks, abrasions and other injury. Protectivewear is used during sport, rugby for example and equestrian sports andother activities where a person runs a risk of injury, for examplebuilding and other trades.

Conventional protective wear may form an integral part of an item ofclothing, for example a shoulder pad, or be provided separately, forexample a shin pad.

One existing arrangement comprises a moulded foam article shaped to fita particular part of the body. There are, however, a number of problemswith this arrangement. The article must be produced in different sizesto fit different people. Provision of different sizes can be expensiveor inconvenient. Also, closely fitting articles can restrict movement ofthe wearer, especially when worn on or near joints.

In DE 43 41 722 is disclosed a cushioning material for the treatment oflymphostatic fibroses in which a plurality of foam elements with anenlarged base are disposed side-by-side with their bases touching on afoundation layer to which they are affixed. The troughs defined betweenthe side walls of the elements enable the material to be flexed to forma pressure bandage. However, the foram elements of the bandage touch oneanother at their base, which restricts the stretchability of thematerial as a whole and is also designed to be worn with the elements incontact with the skin, which would restrict movement.

A moulded foam article can only correctly fit a joint when in oneposition. When the joint moves, the article will no longer fitcorrectly. This may reduce the protection it affords.

In U.S. Pat. No. 3,285,768 is disclosed a fabric coated with a surfacedeformed foam which is manufactured either by grooving or slashing asheet of foam to a portion of its depth and then laminating it to thefabric or by laminating a foam sheet to a fabric and then grooving orslashing the form layer. However, neither of these methods enables thefoam to be cut to define a plurality of spaced, separate elements, whichis preferred if the fabric is to be used in protective wear for ,sportspersons when considerable freedom of movement by the wearer is requiredin addition to comfort.

Another existing arrangement comprises a quilted material includinglengths of foam sewn into pockets formed between two layers of fabric.Such materials are time consuming to produce. Also, such materials cangenerally only easily be flexed in a direction perpendicular to that ofthe strips of foam. Flexing the material in a direction along the lengthof the strips involves flexing the strips themselves which, depending onthe type of foam used, can be difficult. A similar type of garment isdisclosed in U.S. Pat. No. 5,551,082 which describes an athletic garmentin which strategically placed rib-shaped gel, air or foam padding iscontained in envelopes that are individually affixed to an elasticizedfabric shell.

BRIEF SUMMARY OF THE INVENTION

It is an object of the present invention to overcome, or at leastreduce, the problems associated with the manufacture of conventionalprotective material and with protective wear made therefrom.

According to a first aspect of the present invention there is provided amethod of manufacturing a flexible material comprising the steps ofproviding a sheet of a resilient material; cutting the sheet into aplurality of spaced, separate elements using a cutter which is pressedinto the sheet to cut therethrough; making one side of the spacedelements to stand proud of the surface of a jig provided to hold theelements in place; and bonding a flexible, resiliently stretchablesubstrate to one side of the separate elements by heating the substrateeither to active an adhesive applied between said one side of theseparate elements and the substrate or to weld the elements to thesubstrate.

The separate elements are preferably bonded to the substrate with a hotmelt adhesive, although they can be welded thereto using heat to fusethe elements to the substrate.

According to a second aspect of the present invention there is provideda flexible material comprising a layer of separate resilient elementsjoined to a flexible, resiliently stretchable substrate and manufacturedaccording to the method of the first aspect of the present invention.

Such a flexible material can confirm more easily to the body of thewearer than conventional materials, as it is flexible in all threedimensions. It is therefore more comfortable to wear and can accommodatemovement better than conventional materials. When used as a protectivematerial or to form protective wear a single size, or a reduced numberof sizes, can fit many different sized bodies.

As the elements are separate and spaced apart; this facilitates flexingof the substrate to form a curved surface and enables the material toflex in all directions without “locking up” or preventing movement in aparticular direction. This is a particular advantage the flexiblematerial of the present invention has over prior art arrangements whichtend not to exhibit universal flexibility.

The elements preferably comprise a resilient foam material, for examplea closed cell polyethylene, and could comprise a number of differenttypes of foam or other materials to give desired properties, for examplelayers of foam of different densities.

The elements may be substantially identical, alternatively they can beof different size and shape, for example to fit comfortably part of awearer's body, or some other article.

The elements preferably take the form of blocks. They can be of regularor irregular shape, for example hexagonal or octagonal in cross-section.The elements are preferably evenly distributed on the substrate with adensity of between 100 and 8000 elements/m², more preferably between 250and 8000 elements/m², and still more preferably between 4000 and 6000elements/m². In one embodiment, the elements comprise cubes of side 12mm spaced apart by 2 mm. This gives a density of about 5000 cubes/m².This allows the material to flex easily along all directions, animprovement over known quilted protective materials. Also, one type ofmaterial can be cut to many different sizes, for example to formprotective wear of different sizes, without significantly affecting itsability to flex. This is in contrast to known quilted protectivematerials wherein due to the size of the foam strips, the size of eachstrip must be changed to form an article of different size withoutreducing flexibility.

The substrate is resiliently stretchable or elastic and preferablycomprises a fabric, although a resiliently stretchable film or sheetcould be used. This enables the material to adopt a greater range ofconfigurations. Suitable fabrics include knitted nylon and polyesterfabrics and more particularly those materials comprising elastane.

A second layer of a flexible substrate material is preferably bondedover the elements so that they are sandwiched between two layers. Inthis case, as the first substrate layer is resiliently stretchable orelastic, this helps to prevent puckering of one side of the materialwhen it is flexed. Advantageously, both substrate layers are resilientlystretchable. However, in cases where only a single stretchable substratelayer is provided and the material is to be used in a curvedconfiguration the material is preferably arranged so that thestretchable layer lies on the outside surface of the curve.

The material may be comprised in clothing or other wear. It isparticularly suitable for incorporation into protective clothing andwear, for example shoulder pads, knee pads, shin pads, arm bands,head-guards, vests and gauntlets for both humans and animals. It will beappreciated that in these garments the blocks are provided whererequired and omitted from certain areas of the garment. For example, ina headguard no blocks need be positioned in the ear-flaps of the guard.

The material could also be comprised in furniture or upholstery and canbe particularly useful when used with wheelchairs and hospital beds.Spaced part elements can help to reduce the incidence of bed sores. Asthe material is resilient, it comprises a cushioning medium, for,;example for saddles. Where the material comprises a foam layer, thisprovides it with good thermally insulating properties and it can beusefully incorporated into, or used to form wet suits. A foam layer canalso render the material buoyant in water, in which case it can beusefully used in or to form buoyancy vests, life jackets and swimmingaids. When used as a swimming aid, for example, the material can beincorporated in swimming costumes as an aid to the buoyancy of thewearer. It is possible in this case to arrange for the foam blocks to beprogressively removable from the costume as the confidence and skill orthe trainee swimmer increases.

The material may also be used for packaging and cladding.

As indicated above, the elements may not be distributed all over thesurface of the substrate. In particular, there may be a border ofsubstrate having no element thereon. The border may include a fasteningmeans, for example VELCRO(™) to enable it to be affixed to itself or toanother article, say a garment.

In one embodiment, the elements could comprise a series of spaced-apartstrips. Such a material would have different properties when flexed indifferent directions.

Preferably, at least said one side of the elements are coated with thehot-melt adhesive prior to being cut into the separate elements.Alternatively or in addition, the side of the substrate adjacent saidone side of the elements is coated with the hot-melt adhesive. A sheetof hot-melt film may also be interposed between said one side of theelements and the substrate to provide said adhesive layer.

Advantageously, the resilient sheet is cut into a plurality of separateelements using a cutter which acts as the jig after cutting through theresilient material to hold the elements in place while the substratelayer is applied thereto. Preferably, the cutter is adapted so that saidone side of each, now cut, element are made to stand proud of thesurface of the cutter grid. The sheet material may spring back slightlyafter cutting to accomplish this. Alternatively, means, such asejectors, are provided to achieve this effect.

In one embodiment of the method, a sheet of a resilient material isprovided and at least one side of the sheet is coated with a hot meltadhesive. The sheet is placed, adhesive side up, over a cutter gridarranged to cut the sheet into a plurality of elements, for examplesquares. The sheet is pressed down onto the cutter to cut through thesheet. Excess material from between the elements is then removed. Aresiliently stretchable substrate is placed over the, now cut, sheet andheated to activate the adhesive to join the elements to the substrate.The substrate is then lifted away from the cutter, taking the elementswith it.

It will be appreciated that in this embodiment, the cutter grid acts asa jig, holding the elements in placed while the substrate layer isapplied. If the flexible material is to be cut into large pieces, inparticular large irregularly shaped pieces, then these pieces may beassembled into a specially constructed jig to hold them into placebefore application of the substrate. Conveniently, as before the sheetof resilient material from which the elements are cut has an adhesivelayer applied to one or both surfaces prior to the cutting process.

Alternatively, the sheet of resilient material is cut into strips in afirst direction using a plurality of rolling cutters and then cut in asecond direction at an angle to the first direction to the separateelements. Preferably, the rolling cutters are moved sideways after eachcut to cut narrow strips of material in both directions to space theelements apart, the narrow strips of material being removed to leave theseparate elements spaced apart from one another.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Embodiments of the various aspects of the invention will now bedescribed by way of example with reference to the accompanying drawings.

FIG. 1 is an enlarged perspective view of part piece of flexiblematerial according to the invention.

FIG. 2 shows a schematic view of a protective arm band formed from thetype of material of FIG. 1.

FIG. 3 is a plan view of a cutter grid.

FIGS. 4 to 6 are vertical cross-sectional views of apparatus used in themanufacture of material as shown in FIG. 1 at various stagesrespectively throughout the manufacturing process.

FIG. 7 is a cross-sectional view through another embodiment of aflexible material according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, a flexible material comprises a plurality of cubes1 of a resilient closed-cell polyethylene foam, of side approximately 12mm and with corners of radius approximately 2.5 mm, joined with a hotmelt adhesive to a fabric substrate 2. The cubes 1 are evenly arranged,each cube being spaced from adjacent cubes by approximately 2 mm. Thefabric 2 is a resiliently stretchable knitted fabric, preferably onecomprising polyester or elastane fibers.

A margin of fabric 2 is provided around the periphery of the cubes 1.Along the edges of the fabric at opposite ends respectively there arestrips 3 of VELCRO(™), only one of which is shown.

Referring to FIG. 2, a protective armband 4 is shown being worn on partof an arm 5. The armband 4 is formed from a generally rectangular pieceof material of the type shown in FIG. 1 but which in this case comprisesa fabric substrate 6 bonded to both sides thereof with a plurality offoam cubes 7 sandwiched therebetween. Margins are provided at oppositeends respectively of the substrate 6 and a strip of VELCRO(™) 8 isfastened on this margin to enable opposite ends of the material to befastened in an overlaying relationship to form a tube. By varying thedegree of overlap of the ends, the tube can be closely fitted aroundarms of different sizes. The provision of a substrate layer 6 on bothsides of the cubes 7 prevents the latter from separating too much as thematerial is curved around to form a tube. Rather, the substrate 6 on theoutside of the armband is forced to stretch and the edges of the cubes 7at the inner side of the armband are compressed. The provision of asubstrate layer on both sides of the material therefore enables thematerial to continue to provide good protection, even when tightlyflexed.

FIG. 3 shows a plan view of a cutter used for manufacturing the materialof FIG. 1. The cutter comprises blades defining a plurality of squaresof 12 mm side with corners of radius 2.5 mm.

FIGS. 4 to 6 are vertical cross-sectional views of apparatus at variousstages respectively throughout the manufacture of the flexible materialshown in FIG. 1. Referring to these figures, one side of a 12 mm thicklayer of closed cell polyethylene foam 10 is coated with a hot meltadhesive 11. The foam 10 is then placed onto a cutter 12, of the typeshown in FIG. 3, and pressed down with a press 13 so that the cutter 12cuts through the foam 10 to form a plurality of separate cubes. Thepress is then removed, whereupon owing to its resilient nature, the foamwill tend to spring back slightly so that the exposed surface of eachcube stands proud to lie above the surface of the cutter. Excessmaterial from between the elements is then removed.

Next, as shown in FIG. 5, a layer of fabric is placed over the foam andcutter 12 and a heated platen 15 is brought into contact with the fabric14. Heat is conducted through the fabric 14 to the foam and activatesthe adhesive, bonding the fabric 14 to the foam 10. In this arrangement,the cutter grid acts as a jig, holding the foam cubes in position whilstthe fabric substrate 14 is applied thereto.

Then, as shown in FIG. 6, the fabric can be lifted away from the cuttertaking the foam cubes 10 with it.

In an alternative method, ejectors are disposed in the cutter grid toeject the elements, leaving any waste material behind in the cutters.

If the foam 10 is to be cut into large pieces, in particular largeirregularly shaped pieces such as may be suitable for use in anequestrian jacket, then these pieces may be assembled into a speciallyconstructed jig to hold them into place before application of the fabricsubstrate 14. As described above, the sheet of resilient foam from whichthe elements are cut will have hot-melt adhesive applied to one or bothsurfaces prior to the cutting process.

In a further variation, the sheet of resilient material is cut intostrips in a first direction using a plurality of rolling cutters. Thesheet is cut in a second direction perpendicular to the first to formcubes. The cutters are then moved sideways to cut narrow strips of foamin both directions to space the cubes apart, the narrow strips of foambeing stripped away to leave the cubes.

FIG. 7 shows another embodiment of flexible material similar to thatshown in FIG. 1, but with a layer of fabric 16 bonded to each ofopposite sides of tho elements 17. This embodiment may be produced in asimilar way to that shown in FIG. 1 except that opposite sides of thefoam layer are coated with adhesive and, after the foam cubes bonded toa first layer of fabric have been removed from the cutter, a secondlayer of fabric is placed over the exposed surface of the elements arepressed with a heated platen to effect a bond.

In other variations to the above methods, the hot-melt adhesive may beapplied to the surface the substrate rather or in addition to the sidesof the flexible material. Alternatively or in addition, a hot-melt filmcan be interposed between the elements and the substrate.

Also, heated nip-rollers can be used in place of a heated platen to bondthe elements to the substrate, particularly when substrate is bonded toboth sides of the elements, which are thereby sandwiched therebetween.This facilitates passage of the material between the rollers prior toactivation of the adhesive.

Flexible materials according to the invention are more convenient toproduce and more flexible and versatile that known protective materials.They may also be used in a variety of applications including protectivewear and clothing.

I claim:
 1. A method of manufacturing a flexible material comprising thesteps of providing a sheet of a resilient material; cutting the sheetinto a plurality of spaced separate elements using a cutter which ispressed into the sheet to cut therethrough; making one side of theplurality of spaced separate elements to stand proud of a surface of ajig provided to hold the elements in place; and bonding a flexibleresiliently stretchable substrate to one side of the separate elementsby heating the substrate either to activate an adhesive applied betweensaid one side of the separate elements and the substrate or to weld theseparate elements to the substrate.
 2. The method as claimed in claim 1wherein the sheet is cut into a plurality of separate elements using acutter which acts as the jig after cutting through the resilientmaterial to hold the elements in place while the substrate is appliedthereto.
 3. The method as claimed in claim 2, wherein the cutter isadapted so that said one side of each of the cut elements is made tostand proud of a surface of the cutter after cutting through said sheetof resilient material.
 4. The method as claimed in claim 3, wherein anyexcess resilient material located between the plurality of spacedseparate elements is retained in the cutter.
 5. The method as claimed inclaim 3, wherein any excess resilient material is removed from betweenthe plurality of spaced separate elements prior to the elements beingbonded to the substrate.
 6. The method as claimed in any of claim 1,wherein the plurality of spaced separate elements comprise a foammaterial.
 7. The method as claimed in claim 1, further comprising:bonding a second flexible substrate to an opposite side of the pluralityof spaced separate elements to said one side.
 8. The method as claimedin claim 1, wherein at least said one side of the sheet is coated with ahot-melt adhesive prior to being cut into the plurality of spacedseparate elements.
 9. The method as claimed in claim 1, wherein the sideof the substrate adjacent said one side of the plurality of spacedseparate elements is coated with a hot-melt adhesive.
 10. The method asclaimed in claim 1, wherein a sheet of hot-melt film is interposedbetween said one side of the plurality of spaced separate elements andthe substrate so as to provide said adhesive.
 11. The method as claimedin claim 1, wherein the sheet of resilient material is cut into stripsin a first direction using a plurality of rolling cutters and then cutin a second direction at an angle to the first direction to form theplurality of spaced separate elements.
 12. The method as claimed inclaim 11 wherein the rolling cutters are moved sideways after each cutto cut narrow strips of material in both directions to space theelements apart, the narrow strips of material being removed to leave theplurality of spaced separate elements spaced from one another.
 13. Themethod as claimed in claim 1 wherein the substrate is heated by a heatedplaten which either activates the adhesive or melts the surface andthereby bonds the substrate and the plurality of spaced separateelements together.
 14. The method as claimed in claim 10, wherein thesubstrate is heated by passing the substrate and the adjacent pluralityof spaced separate elements between heated nip rollers.
 15. A method ofmanufacturing a flexible resiliently compressible material comprising:providing a first resiliently stretchable fabric substrate; providing anarray of a plurality of separate individual resiliently compressibleelements in a spaced relationship, the individual elements having a topsurface and bottom surface in an array of top surfaces and bottomsurfaces; providing a second resiliently stretchable fabric substrate;contacting the top surfaces and the bottom surfaces of the plurality ofresiliently compressible elements with the first and second resilientlystretchable fabric substrates; and bonding the top and bottom surfacesof compressible elements to the first and second resiliently stretchablefabric substrates so that the elements will be held in a spaced apartrelation with spaces between the elements, the bonding selected from thegroup consisting of adhesively bonding and welding, the fabricsubstrates not bonded to each other in the spaces of about 2 mm and toprovide the flexible resiliently compressible material, wherein a sheetof resiliently compressible material is cut into the plurality ofseparate individual resiliently compressible elements using a cutterwhich acts as a jig after cutting through the resiliently compressiblematerial to hold the elements in place while contacting one of thesubstrates to the elements.
 16. The method as claimed in claim 15wherein the plurality of individual resiliently compressible elementscomprises a foam material.
 17. The method according to claim 16 whereinthe foam material comprises layers of foam having different densities.18. The method according to claim 15 wherein the elements aredistributed between the substrates at a density of from about 4000 toabout 6000 elements/m².
 19. The method according to claim 18 wherein thetop and bottom surfaces have a polygonal shape.
 20. A method ofmanufacturing a flexible resiliently compressible material comprising:providing a first resiliently stretchable fabric substrate; cutting asheet of resiliently compressible foam with a cutter to provide an arrayof a plurality of separate individual resiliently compressible foamelements in a spaced apart relationship, the cutter acting as a jigafter cutting through the resiliently compressible foam to hold theelements in place, the individual elements having a planar top surfaceand bottom surface in an array of top surfaces and bottom surfaces;providing a second resiliently stretchable fabric substrate; contactingthe top surfaces and the bottom surfaces of the plurality of resilientlycompressible elements with one of the first and second resilientlystretchable fabric substrates while the cutter holds the elements inplace; and adhesively bonding the top and bottom surfaces ofcompressible elements to the first and second resiliently stretchablefabric substrates so that the elements will be held in a spaced apartrelation with spaces between the elements, the fabric substrates notbonded to each other in the spaces and to provide the flexibleresiliently compressible material.
 21. The method according to claim 20wherein the foam elements comprise foam with of layers of foam havingdifferent densities.
 22. A method of manufacturing a flexibleresiliently compressible material comprising: providing a firstresiliently stretchable fabric substrate; cutting a layer of foam with acutter grid having cutting edges which go completely through the foamlayer to provide an array of a plurality of separate cut individualresiliently compressible elements which have been cut from the foam andafter cutting are in a spaced apart relationship, the individual elevensbeing spaced about 2 mm from each other, the array of elements havingtop and bottom surfaces; bonding one of the surfaces of the array of theplurality of separate cut individual resiliently compressible elementsto the first resiliently stretchable fabric substrate while the separatecut individual elements are held in the spaced apart relationship with ajig to provide a fabric element combination, the elements of the fabricelement combination held in spaced bonded relationship; providing asecond resiliently stretchable fabric substrate; bonding the secondresiliently stretchable fabric substrate to the elements of the fabricelement combination to the elements on the side of the array oppositethe first fabric substrate so that the elements will be held in a spacedapart relation between the first and second resiliently stretchablefabric substrates with spaces between the elements, the fabricsubstrates not bonded to each other in the spaces and to provide theflexible resiliently compressible material.
 23. The method according toclaim 22 wherein the elements are distributed between the substrates ata density of from about 250 to about 8000 elements/m² between thesubstrates.
 24. The method according to claim 23 wherein the elementsare comprised of layers of foam having different densities.
 25. Themethod according to claim 22 wherein the elements are distributedbetween the substrates at a density of from about 4000 to about 8000elements/m² between the substrates.